Pile fabric texturing due to pile overlaps



Jan. 6, 1959 F. w. E. Hoi-:SELBARTH 2,867,244

PILE FABRIC TEXTURING DUE To PILE ovERLAPs Filed May 17. 1954 9 sheets-sheet 2 Jan. 6, 1959 F. w. E. HOESELBARTH 2,867,244

PILE FABRIC TEXTURING DUE TO PILE OVERLAPS 9 Sheets-Sheet 3 Filed May 17. 1954 wef- Jan. 6, 1959 F. w. E. HoEsELBARTH 2,867,244

PILE FABRIC TEXTURING DUE TO PILE OVERLAPS Filed May 17. 1954 9 Sheets-Sheet 4 w. E. HOESELBARTH 2,867,244

PILE; FABRIC TEXTURING DUE To Pm: ovERLAPs Filed May 1v. 1954 Jan. 6, 1959 9 Sheets-Sheet 5 Jan. 6, 1959 F. w. E. HOESELBARTH 2,867,244

PILE FABRIC TExTuRING DUE To Pm ovERLAPs 9 Sheets-Sheet 6 Filed May 1'?. 1954 1N V EN TOR. a rf Jan. 6, 1959 F. w. E. HoEsELBARTH 2,867,244

PILE: FABRIC TEXTURING DUE To PILE ovERLAPs Filed May 17. 1954 9 Sheets-Sheet '7 Aarzzeys- Jam 6, 1959 F. w. E. HOESELBARTH 2,867,244 .Y

PILE FABRIC TrvIxTuRING DUE To PILE ovERLAPs Filed may 17. 1954 9 sheets-sheet a r f r r r r r a j .I S E 4 f INVENTOR ATTORNEYS.

Jan. 6, 1959 F. w. E. Hol-:SELBARTH 2,857,244

PILE FABRIC TEXTURING DUE To PILE ovERLAPs Filed may 17. 1954 9 Sheets-Sheet 9 ATTORNEYS nited States Patent O i PILE FABRIC TEXTURING DUE T PILE 'i OVERLAPS Frank W. E. Hoeselbarth, Carlisle, Ia., assignor to C. H. Masland & Sons, Carlisle, Pa., a corporation of Ivenn- Sylvania' Application May 17, 195'4, serial No. 430,295 6 Claims. (Cl. 139.-f40 3) The present invention relates to pile fabrics such as carpets and rugs in which textured effects on the surface of the p ile are obtained by special thread-ins using two or more pile warps. This application has been divided, the subject matter relating to the method being contained in my copending application Serial No. 494,756, led March 16, 1955, for Texturing Due to Overlaps.

A further purpose of the invention is to create ktextured effects in pile fabrics such as carpets and rugs by a combination of zones'of warpwise oriented'pile and of zones of turned or dislocated pile.

' The subject matter relating to the pulling out of cut p ile ends originally contained in this application has been transferred to my copending application, Serial No. 626,059, filed December 3, 1956 for Pile Fabric.

A further purpose is to weave a pile fabric using two or more pile warps in the face of the fabric according to the velvet or tapestry system, and to obtain unusual effects by threading inA a series of groups of ends of a rs'twarp in adjoining dents, with dislocations between the groups of ends-in, and a series of ends of a second warp' in adjoining dents, with dislocations in dents between groups of ends-in, dents at the sides of groups of thefrst' warp corresponding to dents at the middle or an interior position of groups of the second warp.

A further purpose is to secure distributions of mass of pile by a combination of differences in, wire height, s'traightness or waviness, cutting or noncutting character,

or other wire-imposed characteristic, on the one hand,

and orientation of Zones of upstanding ends of two or more pilel warps concentrated, and intermediate overhanging pile extending from one row to the next where pileends, are sparse.

A further purpose is to place pile A in a locally relatively concentrated relationship by bringing ends of pile A locally more close together in adjoining courses than elsewhere in the pile (reversing the left to right relation toA pile B) or by keeping an end of pile A and an end of pile B in each such course, when an end of pile A or 'pile B is omitted in some other course.

l"A further purpose is to attenuate pile A locally at a partcular'courise or courses by omitting Vpile A in the particular course or by lspacing it more widely from pile B by" reversingthe order from left to right of ends" of pile A and pile vB in adjoining courses.

' A further*y purpose is to cut ends of one of two or more Vpilerwarps wovenin opposition by one wire7 and when the next wire raises the same ends of the same pile warp to pull out the cut ends and expose them at the face of the fabric by the inclined portions in the shed on a wavy wire.

Further purposes appear in the specification and in the claims. Y

Inthe. drawings I have chosen to illustrate a few only of the numerous embodiments 1n which my invention may. appear, selecting the forms shown from the stando pointsofconvenrence in illustration, satisfactory operag2,867,244 Patented Jan, 6, 19,59

tion and clear demonstration of the principles involved. I Figure 1 is a warpwise conventional weave diagram showing one example of a Weave which may be ern p loyed in the present invention.

' Figure 2 is a transverse thread-in or draw'up diagram showing they ends-in and the ends-out in particular dents for each of two pile warps. These and other thread-in diagrams omit from each dent the binder warp ends and stuifer warp ends.

` Figure 3 is a transverse thread-in or draw-up diagram showing the pile warps arranged in groups of three ends rather than in groups of live ends as in Figure 2.

Figure 4 is a transverse thread-in or draw-up diagram showing the warps` arranged in groups of three ends with overlapping only at one end of each group, whereas in the other forms the overlapping is at both ends.

Figure 5 is a transverse thread-in` or draw-up diagram showing overlapping in two dents at each end of each group, whereas in other forms the Ioverlapping i's only in one dent.

Figure 6 is a photograph showing the face of ay weave in which the groups on4 one warp contain five ends and those on the other warp show four ends, all wiresl are straight and non-cutting, the high wires have a height of 0.290 inch and the4 low wires have a height of 0.130 inch, and the sequence of wires in the wire set runs two low wires in sequence, three high wires in sequence, then repeat with two low wires in sequence,A etc.,

Figure 7 is a photograph of theY face of aV fabric avc,- cording to the invention in which the groups of ends for each of the two pile warps include respectively live and four ends,` all wires are straight and noncutting, the high wires have a height of 0,50() inch,` the low wifrs have a height of 0.130 inch and the sequence of wires runs two low wires in succession, one high wire, then repeat with two low wires in succession, etc.

Figure 8 is the photograph of the facey of fabrie in accordance with the invention inA which the groups and the wires are as in Figure 7, and the sequence` of wires runs two high wires in succession, one low wire` in succession, and then repeat with two high wires in succession, etc.

Figure 9 is a photograph showing the face of a fabric woven according to the invention using all noncutting wavy wires, the high portions having a heightof 0.323 inch and the low portions a height of 0.130 inch. There are five pile warp ends in each group on` each of the two pile warps. The pile wires are used in sequence according to a pattern asvshown.A

Figure 10 shows the face of a pilefabric according to the invention which is woven from two pile warps with ve ends in each group. The wires used are wavy noncutting wires having high portions of 0.323 inch and low portions, of 0.130inch, of height of 0.130 inch. The sequence used is two wavy noncutting wires, two straight cutting wires, one. wavy noncutting wire and then one straight cuttingwire,` fol,- lowedV by the repeat. Atv many points as shown, the low portions ofthe wavy wire4 have pulled-out portions which were previously cut by a cutting wire due to the fact that the same pile warp is thenraised over a wavy noncutting wire.

Figure 171 is a fragmentary side elevation of a wavy wire used in the invention.

Figures 12,13', 14 and 15 are transverse thread-'incr draw-up diagrams showing groups in which the relative right and left hand relationships of ends of pile warp A to pile warp B in an individual dent differs in sornecases at different'postions in the group, for example, between the middle and one end or between opposite ends.

Figure 16 isa photograph showing the face of a weave according to Figure 12.

and straight cutting wires A Figure 17 is adiagrammatic top plan view showing been obtained by `weaving two ory more pile warps raised j successively over wires, and employing Vends-in of a particular warp at dents atv which ends are out of another pile warp. Y Y

l lIn accordance with the present invention, improved textured effects are obtained by creating a series of zones of straight pile due to concentration of a particular pile Awith intermediate zones of pile which .falls over into the next transverse row because ends of pile A are scarce. The invention can be employed where two or more pile warp ends are ineach group, it being understood that the number of pile warp ends in the groups of a particular warp may be the same throughout or different throughout, and may be the same or different from the number of pile warp ends in the groups of the cooperating pile warp or pile warps. It is likewise possible to overlap the groupsV in the'different pile warps to the extent of only a single dent or to the extent of two or more dents. Likewise the overlapping may take place at one or both sides of the groups. Y

The groups in pile warp A and in pile warp B are characterized by the existence of areas of'crowding across the fabric. In some cases the areas of crowding are created by ends-outs between the groups. In other cases thegroups are separated by differences in the right and left hand relationships of an end of pile warp A with respect to an end of pile warp B in the same dent in different parts of the group.

The concept of differences in right and left hand relationsliip of pile 'warp A and pile warp B will be best understood by reference to Figure 17 lwhich shows two courses divided by splits 32 which of course extend vertically, b'ut for convenience in illustration are here extended longitudinally in plan. VIn each of the dents 58 and 6i) there appear ends of stufler warp 26 and of pile warp 2li and pile warp 2111 The stulfer warp is threaded through bottom long slots of heddle frames St and 57, while the ends of pile warp 21 are carried through relatively upper' eyes 61 on heddle frame 56 and Vthe ends of pile warp 20 are carried through relatively upper eyes 62 on heddle frame 57. The stulfer warp 25 is Vrelatively straight. In dent 58 as viewed in Figure 17 pile warp end 20 is and the relatively heavily tensioned stulfer warp end is between. in dent 60 on the other hand pile lwarp 20 is on the left and pile warp 21 is on the right with the relatively heavily tensioned stulfer warp end between.

In other cases, the groups are separated by a combination of ends-out and differences in the right and left hand relationships of an end of pile warp A with respect to an end of pile warp B in the same `dent Vin different parts of the group. Thus, the change in right and left hand relationship may be between the between one end of the group and the other end of the group as illustrated herein. Y

Figure 1 illustrates one of many weaves to which the invention may be applied, it being understood that it is immaterial from the standpoint of the present invention whether there be a single binder warp lwoven in opposition to the stuter warp or a pair of opposed binder warps, and itis also immaterial whether the weave is a V weave, a W weave, or any other suitable pile fabric construction.

It is likewise immaterial whether two, three or any other number of pile warps are successively raised in middle and one end or 33 occupied by the pile according to the Carlisle weave (cam operated multiple pile warp carpet loom).

As seen in Figure 1, pile warp 20 is woven in opposition to pile warp 21, pile warp 20 being locked below every alternate face weft 22, and pile warp 21 being locked below the intermediate, face wefts. The backing of the fabric is constructed by opposed binder warps 23 and 24 woven around face wefts 22v and back wefts 25, with a stuffer warp 26' extending between the face and back wefts.

The successive pile warps 20 and 21 are irraised over p wires 27 and 27 which will preferably be different, and

may successively differ as to the character of wires raising each pile warp as laterexplained. The differences between the wires 27 and 27 will suitably be in any one or any combination of thefollowing features:

(l) Height of straight or noncutting wires.

(4) Relationship between the character of a particular y wire and the wire which last previously raised the same pile warp.

(5) Relationship between the'character of a particular wire and the immediately preceding wire which raised the other pile warp.

ToVV illustrate this difference, wires 27 show optional cutters 28 applied at the ends opposite to the heads.

Figure 2 is a draw-up or thread-in diagram according to the invention, showing a series of dents 31B of thereed 31 separated by splits 32 and each defining a course in the weaving of the fabric. A line 20 is extended across the diagram to show the ends which correspond with the pile warp 20, it being evident ,that they are arranged in groups 33, in this case having tive members in each group," and occupying `.tive adjoining dents. In between each group33 contained in dents 34 which are occupied by ends of theV pile warp Ztl, there are dents 35 which have ends-out or contain no pile warp endsrof the pile warp 2). The number of these unoccupied dents 35 de@` pends upon the number of `ends in the groups of the succeeding pile warp 21. Pile warp 21 has ends Vwhich are shown by their crossing the line 21 in Figure 2. Groups vof ends 36, in this case five in number, are placed in adjoining dents 37, the intermediate dent or dents of which correspond to the dents 3S which are un'- occupied by the pile warp 20. However, the side dents A `occupied by ends of the groups 33 of pile warp 20'.

on the right and pile warp 21 is on the left,

Thus we have in the middle of each of the groups ends which are alone in their dents as far as the pile 'warps t are concerned, but at the sides there are overlaps or dents occupied by both pile warps.

The condition created in the vfabric is indicated in Figure 8. In courses or dentsr38 there are holes or `recesses created in the fabric at`40. The pile 41 or 42 remote.v from these holes or recesses remains oriented warpwise in the normal manner, but the pile 41 or 42 adjoining these holes or recesses becomes turned when viewed from the face of the fabric because the recesses give room for expansion and rotation of the loops. This `rotation produces a dislocational effect which imparts texturing to the fabric. This texturing is very novel and attractive and cannot be obtained in any other manner.

The invention is applicable with any desired number of ends in the particular Figure 3 shows a seriesy of dents 20 has three ends in each group three ends in each group. The intermediate end inreach group is in a dent 44 which corresponds with an end-out in the other pile warp,but the sidemost ends of each group are in dents 45`which have ends of both groups and therefore create upstanding pile.

Figure 3 illustrates a feature respect to the texturing effect.

43 in which pile Warp which is significant in .Considering the' group of (2)4 High and low varianttcharacter of the top of the the groups 36 of pile warp 21 are also groups greater than two. Thus Y and pile warp 21 hasV inclusive,

ends'39 of pile warp 2.1, itwill be noted that in dent 45*2 at one'side of the group 39 the end of pilewarp 20 isY to the left' of' the'Y end of pile warp 21 in the dent, but at the right side ofthe group 39 in dent 453 to the end of pile warp20 is to the right of the end of pile warp 21. There is thus a reversal ofthe right and left hand relationships of the p ile warp ends in the dent between the opposite sides of the' group. The same effect occurs' all the wa'y vacross 'the' fabric. Thiss'erves to produce alless i u lto the distinction beint'ense textuiing, YY1t3ut` contributes tween one group and the next. v I

`rThe invention also applicable with overlap only at one s'ideiofeach'group rather "thanat both sides as shown in .Figure 4. Inthis form, v'there arethree ends in each group of'pile warp 20 and of pil'e'warp 21. The middle end of each'gro'p" is iii dent'j'4'4`wher`e there is an end-out of the other group, the one lendrnost endis in a dent 45 which has'air end of both pile warps and therefore" has oerlp', but the 'other sidernost end of 'ea'ch group is in la'. dent'441jT which has an end-in of one warp andan end-out of theother'pile and therefore has no vab'. i

The-'invention is also applicableto cases in which the overlap covers two or more :dents rather than only/"one dent asloiig as thereare'intermediate' dents of each group without overlap. Thus, in Figure there 'are six pile warp ends in each group. Intermediate ends are in dents 44 whichhave Yan ehd of one pile warp but no end of the other pile warp. At the sides of each groupv there are two dents 45 and 45l which have an end ofeach pile warp in the parfticilr dent. KAThe pos'y 'ble 'effects' are illustrated in Figures 6. to ch""s'ho"v`v 'combinations of upstanding and denying Figure' @fas 'earlier explained, employs a combination of high and low straight, noncuttin'g wires, with different numbers ofends in the groups of the particular' pile warps (respectively 5 and 4).' It' will be noted that'v the high pile' is displaced 'out of'the straight row and into, the next in a series of scroll formations which are most attractive.

In Figure 7 the high vpile is actually distorted into a dfagonal formation by the effect of the overlap` and the ends-ont. Pronounced lining elects, however, are broken up and an attractive appearance is obtained.

In Figure 8, again using uncut pile as in the other igures, the sequence is such as to shift a particular pile from the high wires to the low wires and back again, using two pile warps.

Figure 9 employs wavy wires in a noncutting construction, and the variation in heights due to the wires are accented by the eiect of crowding particular pile projections over into adjoining transverse rows.

In Figure 10 there is a combination of cut and uncut pile projections, but due to the fact that the wire shifts at a particular pile warp from one type of wire to another, a particular warp which has been cut to form low cut pile in one transverse row appears over a noncutting wavy wire the next time it is raised in the fabric and the pulling of the wavy wire completely pulls some of the ends out, leaving abnormally long tufts sticking out which enhance the appearance, and are in the same row with loops. Those loops woven over high portions 46 of the wavy wire (Fig. l1) are not pulled out, but only those woven over relatively low portions 47 or lower parts of inclined portions 48.

Figures l2 to 15 indicate the results which can be achieved in texturing by shifting in some cases the relative right and left hand position of the ends of pile warps and 21 in the dent at different positions in the groups.

Figures 12 and 13 have the same number of ends per group, and the same number of ends-out between groups, but different left and right hand relationships of pile warp ends of pile warps 20 and 21 in an individual dent.

Considering first Figure l2, the dents may be designated for the present purposes as 50,151', 52 and 53, theud'esignatio'is then repeating in ii'ew'cycles ffur'- dents across the lorn'. lIndividual ends" of pile warp appear-'in each case in dents v50, 51 and 52, "whil'e'pile warp'"2'1 has 'an end-out in de nt' 53'.' This samerelationship occurs all the way across 'the fabric in-"they weftwisdirection in'a series of cycles. i

Th'egrou'psV of three adjoining pile warp ends of-vpile warp 2f) are :staggeredwith respect to the groupsof'th'ree adjoining "pilewaipends of pile warp l spective groups overlapfat the'ends, but the middle o'fgeachV group i's opposite anend-o'ut of t-he adjoining groupy of the Vother pilel warp.AY Thereforethe endsin of pile warp 2.1'v appear in dents 52, 53 aud'SAil,v with an end-out in dentS'l.

' In the thread-in of Figure 12, wherever pile warp en ds of pile warps 20 and 21 both appear in the same dent, the

end of pile warp 21 is threaded-in to the right of end of pile warp 20. This serves to divide up the groups ofV ends and give a"textu`r"e4 which 'is r'riore intense" than that of Figure 13 discussed below(l The photograph of Figure 16'V shows the texture obtained in Figure 12, and illustrates clearly this effect'.

In Figure 1'3., pile warp 20 has an end-in in each dent 50,'51 and 52 and an end-out in each dent 53, while pile warp 21 has an end-in in each dent 52, 53'and 50 andan end-'out in each dent v51. At the left 'hand side` of each group of pile warp 20 and at the right hand side of each group of pile warp I21, ends of these pile warps are present in dent 50, and the e`nd of pile warp 20. is placed to the right ofthe end of pile warp 21. On the other hand, at the right hand sideof'l each group ofy pile warp 20 and the leftl hand side of each group'of pile'warp 21, an 'end ofy pile warp 20 and an'end of pilewarp 21 are present in dent 52. ln this case, the situation is" just the reverse, andthe end of pile warp 20 is to the left of the end 'of pile warp 21. The iinaleffect is to contract the group and make the texture less intense. Itis not, however, necessary in every case to employ ends-out between groups. Figure 14 illustratesya threadin. in which the ends of pile-warp 20 which form the group are in dents 5(7), 51", 52, and 5.3, while the ends ofpile warp 21 whichform the'g'roup are in dents 52, 53, 50 and L51." ThereY areno ends-out between groups but a reversal occurs in right and left hand relationship. Thus at the left hand side of the group of pile warp 20, in dents S0 and 51, the end of pile warp 20 is to the right of the end of pile warp 21. At the right hand side of each group in pile warp 20, in dents 52 and 53, the pile warp-end of pile warp 20 is to the left of the pile warp end of the pile warp 21. A similar situation exists in the gro-ups of pile warp 21. Thus at the left hand side of the group in pile warp 21, in dents 52 and 53, the end of pile warp 20 is to the left of the end of pile warp 21.

vAt the right hand side of the group in pile warp 20 in dents 50 and 51, the end of pile warp 20 is to the right of the end of pile warp 21. Thus in Figure 14 the groups are delineated by the change in the right and left hand relationship of the ends. While this shows the discontinuity separating groups of four ends, the same practice can be used to separate groups of 2, 3 or more ends without using ends-out between groups.

Figure 15 shows a construction having groups of two. The groups of pile warp 20 appear in dents 54 and 55 and the groups of pile warp 21 appear in dents 55 and 54. In dent 54 the pile warp end of pile warp 20 is always to the right of the pile Warp end of pile warp 21. In dent 55 the pile warp end of pile warp 20 is always to the left of the pile warp end of pile warp 21.

It will thus be understood that the reversal of the sidemost ends of the groups causes the separation of the groups.

The same relationship which occurs in the dents above referred to as to the weave persists in the courses of the fabric.

21, so -that the rei plurality of symmetrical In view of my invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art to obtain all or part of the benets of my invention without copying themethod and fabric shown, and I, j therefore, claim all such insofar as they fall within the ofi pile ends of the first pile Warp and also of pile ends ofthe second pile warp respectively out of phase with one another, the middle of each group ofpile ends of one pile warp corresponding tothe side of the adjoining group of pile ends of the other warp, within each. group the pile ends of one pile warp extending continuously with an end in each course, and the groups lbeing sep.- arated by at leastV one course having no end of the particular pile warp, at the positions at which one group terminates and Ianother group begins the pile being deflected laterally to form the periphery of one of the islands.

2,. A pile fabric of claim l, in which in each group the relative lateral positions of the pile ends of each pile warp set differ at the opposite sides of the group. f

3i A. pile fabric having distributed over the face thereof a plurality of symmetrically textured islandsstanding outvabove the ground level of the face kof the fabric, having at least two pile warps, at least one binder warp, a stuer warp and wefts interwoven together, the pile warpsl being raised in successive transverse rows of pile projections, there being laterally of the fabric in each of the pile warps a seriesvof symmetrical groups o'f pile warp ends, one group of one pile warp being out of phase with the adjoining groups 4of the other pile warp so that lthe middle of a group of one pile Warp is opposite the `side of an adjoining -group of the other pilewarp, eachI of the groups having a single end of one of the pile 2,285,332 Gebert .Tune 2, 1942 l2,430,559 Y Dacey Nov.f11, 1947 2,575,029 Shuttleworth Nov. 13, 1951 2,576,791 Jackson Nov.'27, 1951 2,609,839 Groat a Sept: 9,' 1952 2,650,621 Crawford `Sept.'1, 1953 j 2,670,013 Groat Feb. 23, 1954 2,674,269 Groat Apr. 6, 1954 2,708,457 Gebert May 17,1955 2,708,458 Gebert May 17,'1955 2,754,856 Hoeselbarth July '17, 1956 FOREIGN PATENTS 273,409

warps in each of the courses', and thergroups being defined at the sides by a reversal of the lateral relationship of pile warp ends of the different fwarps to'lone another.

4. A`pile fabric of claim 3, having ends out of aparticular pile warp in yat least one course between` one group and the next of the same pile warp.. Y

5. A pile fabric having pile concentrations distributed over the face of the fabric balanced in warpand Vweftwise direction on the principle of a checkerboard, andin the pile fabric two different pile warp sets forming the face of the fabric, at least one binder warp set, astuHer warp set and wefts interwoven together, the pile warps l of the different sets ybeing raised in successive transverse rows of pile projections, there being only one pile warp end of each pile warp set in any'course where'the particular pile warp Vset appears,vthere being in a plurality of adjoining courses one pile warp end ,ofeach of the different pile warp sets, and the pile warp ends of the different pile warp sets reversing their `lateral relationship to one another in different courses, ythe reversals of lateral relationships of the pile warp ends of the diierent sets to one another occurring in a repeat across the width of the fabric, and said reversals producing oriented pairs of concentrated pile projections. v Y

6. A pile 'fabric of claim 5, in which said reversals `alf ternate in successive adjoining courses. f

References Cited in the ile of this patent i UNITED STATES PATENTS Great Britain yJuly, Y6,1927 

